Faculty Publications
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Item Thermal expansion and microstructure evolution of atmospheric plasma sprayed NiCrAlY bond coat using in-situ high temperature X-ray diffraction(Elsevier B.V., 2023) Abhijith Vijay, V.; Santhy, K.; Govindarajan, G.; Rajasekaran, B.The paper focuses on in-situ high-temperature X-ray diffraction (HT-XRD) study on atmospheric plasma sprayed NiCrAlY coating. The sample was in-situ heated from 25 °C to 1150 °C in a controlled atmosphere (3 × 10−4 bar), and the corresponding X-ray diffraction patterns for different temperatures were recorded. The effect of temperature on crystallite size, lattice strain, and coefficient of linear thermal expansion was studied. Major phases identified are γ-Ni, γ’-Ni3Al, β-NiAl, and α-Cr. The formation of stable α-Al2O3 and spinel was found above 1000 °C. The transformation of β to γ’ and γ phase was observed as a function of temperature. The equilibrium phases and the thermal expansion of disordered Face Centered Cubic (FCC) and Body Centered Cubic (BCC) phases were predicted and supported by Thermo-Calc prediction for the stable temperature range. Results showed that the non-equilibrium microstructure produced by thermal spray process did not alter the thermal expansion behaviour. In-situ treatment resulted in microstructure and elemental homogenization. The thermal expansion and mechanism of phase evolution were discussed. © 2022 Elsevier B.V.Item High Velocity Air Fuel Spraying for Surface Restoration of Worn-out IN718(Springer, 2025) Sreerag, M.P.; Abhijith Vijay, V.; Babu, N.N.; Ali, S.S.; Cadambi, S.; Rajasekaran, B.This study explores the efficacy of high velocity air fuel (HVAF) spraying for repairing worn-out IN718 thrust collars used in the chemical industry. We investigated the characteristics and application potential of thick IN718 depositions for surface restoration, focusing on their adhesion. To evaluate microstructure and adhesion, approximately 2-mm-thick IN718 layers were deposited onto IN718 wrought coupons. The HVAF-sprayed layers were notably dense (99.5%) and exhibited excellent hardness, reaching 450 HV0.3, which suggests superior mechanical properties compared to the bulk material. A three-point bending test was conducted to assess the adhesion strength of these thick deposits. The results demonstrated excellent adhesion in both compressive (1281 MPa with > 2% strain) and tensile bending. Trusting in these promising substrate-layer interfacial adhesion characteristics, the investigation was extended to demonstrate the refurbishment of an actual worn-out industrial IN718 thrust collar. A 2-mm-thick IN718 deposition was applied to the entire worn area, and excess material was subsequently machined to achieve the desired surface finish for reuse. Overall, HVAF spray technology shows significant promise for developing thick metallic layers with excellent interfacial adhesion, providing a robust and viable solution for effectively refurbishing heavily worn metallic components and extending their service life. © ASM International 2025.